Dispensing pouch containing premeasured laundering compositions and washer-resistant dryer additive

ABSTRACT

A dispensing pouch containing premeasured laundry compositions comprises a flexible, porous pouch having a plurality of valves or supplementary openings along its edges. The dispensing pouch permits rapid dispersion of a highly soluble laundry detergent through the pouch valves, which open as the pouch is compressed during laundry agitation in a machine washer. Washer-resistant fabric softener/antistatic chips larger than the pouch valve openings remain inside the pouch through wet cycles, to be dispensed as they melt and wick through the porous pouch fabric in a machine dryer.

BACKGROUND OF THE INVENTION

The present invention generally relates to articles for dispensingfabric laundering compositions in automatic clothes washers and dryers.Compositions which are typically added to machine clothes washers anddryers during the laundering process include detergents and fabricsoftener/antistatic agents. In one aspect, the present invention relatesto laundering composition dispensers which provide timed release oflaundering agents during the laundering cycle. In another aspect, thisinvention provides a fabric softener/antistatic composition which, whencontained in a suitable dispenser, remains substantially inactive duringthe wash and rinse cycle yet dispenses during the drying cycle. Thepresent invention also provides a detergent composition which rapidlyand completely dispenses during the wash cycle when contained in thedispenser of the present invention.

Introducing laundry additives into automatic washers and dryers inspecific quantities at precise intervals has long been a problem forconsumers and the detergent industry. Conventional laundering techniquesinclude measuring an effective amount of detergent to be added to thewasher at the beginning of the wash cycle and repeating the step for afabric softener/antistatic agent during the rinse cycle. Althoughattempts have been made to reduce the number of steps necessary to adddetergent and fabric softener/antistatic agents to clothes during thelaundering operation, to date these efforts have achieved only limitedsuccess. It whould therefore be desirable to provide a clean, neat,reliable method of introducing both detergent and fabricsoftener/antistatic agent at the beginning of the wash cycle in asingle, pre-measured, disposable pouch.

Most fabric softener/antistatic compounds provide softening andantistatic action by depositing cationic particles onto fabric surfaces.They impart desirable qualities such as pleasing tactile properties,reduction of static electrically and the adherence of dirt and dustparticles, reduction of fabric wrinkles and generally permit treatedfabrics to be more easily separated following the drying cycle.Typically, fabric softener/antistatic compositions contain a cationicquarternary ammonia compound. These positively charged particles,however, interfere with anionic soil components as well as with anionicsurfactants which are present in many conventional detergent compounds.This charge attraction between cationic and anionic components formsunwanted precipitates which may accumulate on fabric surfaces commonlyin the form of redeposited soil. In order to eliminate this source ofinterference, it is desirable to keep anionic and cationic componentsseparated during the laundering process.

Different approaches have been taken in the past in attempting toeliminate this charge interference. In U.S. Pat. No. 3,267,701 toMandarino, it is suggested that fabric softener/antistat compositions beadded during the drying phase only. This requires a two-step procedurefor adding detergent and softener, which procedure is similarlydisclosed in U.S. Pat. No. 3,947,971 to Bauer, U.S. Pat. No. 4,098,937to Mizuno et al, and U.S. Pat. No. 4,149,977 to Morganson et al. BothMizuno and Morganson suggest that their reusable softener dispensers beattached to dryer vanes for multiple cycles, which is impractical inlaundromat-type settings.

U.S. Pat. No. 4,082,678 to Pracht et al discloses a multiple chamberpouch design with a pH-sensitive inner pouch containing a fabricsoftener. The outer pouch releases a pH modifier which delayssolubilization of the inner pouch until the pH-neutral rinse cycle. Asimilar approach is taken in U.S. Pat. No. 4,108,600 to Wong whereindividual fabric softener particles are coated with a pH-sensitivematerial. U.S. Pat. No. 4,113,630 to Hagner discloses a large softenerimpregnated, insoluble substrate which contains a detergent.

In U.S. Pat. No. 4,203,851 to Ramachandran, detergent builder beads areimpregnated with fabric softener. In U.S. Pat. No. 4,259,373 toDemessemakers et al, a double layered porous pouch releasably contains afabric softener/antistat composition.

SUMMARY OF THE INVENTION

The present invention is based on the discovery that the timed releaseof laundry additives can be achieved by enclosing a washer-effectiveagent and a dryer-effective agent in a heat-resistant pouch made of aflexible, porous, preferably hydrophobic fabric having multiple sidesupplementary openings or valves for the release of detergent particles.A suitable washer-effective agent is disclosed which has rapidsolubility characteristics and which fully disperses from the preferreddispenser at the beginning of the wash cycle. A dryer-effective isdisclosed which resists deterioration and dispersion during the wash andrinse cycles, yet which disperses from the preferred dispenser at aneven, controlled rate during the dryer phase. In the preferredembodiment, the washer-effective agent comprises a detergent formulatedto resist caking which contains a prehydrated sequestering agent tofacilitate rapid solubilization of the detergent composition. Thepreferred dryer-effective agent comprises a fabric softener/antistaticcomposition which is formed into uniform flakes or chips which resistdeterioration and solubilization during the wash and rinse cycles andwhich remain inside the dispenser until such time that they arecontrollably released during the fabric drying cycle.

The method of the present invention involves placing the preferred pouchcontaining both the preferred detergent and preferred fabricsoftener/antistat into a machine washer at the beginning of the washcycle along with fabrics to be laundered. The dispenser is left in thewasher throughout the wash cycle during which time substantially all ofthe preferred detergent composition is released into the wash liquor.The fabric softener/antistat remains substantially inactive inside thedispenser during both the wash and the rinse cycles. The dispenser iscarried over along with the laundry to the dryer where the fabricsoftener/antistat flakes melt and wick through the walls of thedispenser at a controlled rate. The fabric softener/antistat istransferred from the exterior pouch surface to the treated laundry asthe pouch comes into contact with the clothing load during tumbling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the pouch of this invention.

FIG. 2 is a fragmentary cross-sectional view in the direction of arrows2--2 of FIG. 1, with the vertical scale being somewhat exaggerated forclarity.

FIG. 3 is an enlarged fragmentary cross-sectional view in the directionof arrows 3--3 of FIG. 1.

FIG. 4 is an enlarged perspective view of a typical chip of fabricsoftener/antistat in its preferred shape.

DETAILED DESCRIPTION OF THE INVENTION The Dispenser

The dispenser which contains the laundry-effective agents is made of aflexible fabric material having a texture which does not substantiallyabrade typical fabrics laundered by machine washers and dryers. Thematerial should be strong enough to resist tearing and specificallyshould have sufficient tear resistance when wet to remain intact whensubjected to the turbulence encountered during the machine launderingprocess.

The dispenser material must further withstand the heat of machinedryers, which may reach 90° C., in some dryers for periods in excess ofan hour, without undergoing significant chemical or physical changes.While other methods may be suitable, for example sewing or gluing,preferably the dispenser material should be such that it can beheat-sealed by ultrasonic means or the like to form a pouch. Althoughthe specific dimensions of the pouch may vary somewhat, it has beenfound that a rectangular pouch having dimensions in the range of aboutfour inches in length and four inches in width to about eight inches inlength and eight inches in width, with a nominal unfilled thicknessdictated by the pouch fabric type and weight, provides an internalchamber of sufficient size to contain an effective amount of laundryagent, yet allows for convenient manufacture and packaging. Mostpreferred is a pouch five inches long and five inches wide.

The pouch material must have sufficient porosity to allow rapiddispersement of the washer-effective agent while retaining thedryer-effective agent until the drying cycle. During the drying phase,the porosity must be such that the dryer-effective agent is released atcontrolled rate. The fabric porosity must be sufficiently small toprevent the pouch contents from penetrating the pores or "dusting out"prior to introduction of the pouch into the washer. In the preferredembodiment, the pouch porosity allows for release of fabricsoftener/antistat during the dryer phase at an even rate with at leastabout one-half to one gram of the fabric softener/antistat beingdispensed by the end of a typical drying cycle of about 25 minutes to anhour and a half.

The preferred pouch material should also be essentially hydrophobic. Byessentially hydrophobic, it is meant that the amount of water absorbedby the pouch fabric in the washer is small and evaporates in the dryerbefore typical laundried fabrics become dry. This feature permits thepouch to heat to the melting point of the preferred fabricsoftener/antistat flakes quickly so that fabric softener/antistat isdispersed throughout the drying cycle.

Suitable fabrics which may be employed in the construction of the pouchof this invention include non-woven, spun-bonded polypropylene,polyethylene, polyester, polyvinyl chloride, cellulose acetate,polyacrylic, or other materials possessing similar properties, whichwill be known by those skilled in the art. Although some natural fabricsmay be acceptable, most natural fabrics are not sufficiently hydrophobicunless treated with an insoluble coating. Other materials which may beuseful in constructing the pouch of this invention are the open celledfoams known to the art, such as urethanes. Depending on the type offabric utilized, best results are obtained when the average dry weightof the fabric is in the range of 1.5 ounces per square yard to about 1.8ounces per square yard. It has been found that non-woven, spun-bondedpolypropylene having an average weight per square yard of 1.5 ounces,such as that manufactured by the Kimberly-Clark Company under thetrademark Duraguard, is especially preferred.

In the preferred embodiment, a single piece of porous fabric is formedinto a rectangular pouch by wrapping it around a hollow vertical mandreland ultrasonically heat sealing a vertical or longitudinal line ofjoinder where the two longitudinal edges of the fabric overlap. Atransverse row of intermittent heat-sealed lines provides a partialclosure of the lower edge of the tube, and, as will be further explainedbelow, prevents premature dispensing or dusting of the contents from thepouch while permitting enhanced flow of water into and out of the pouchduring the wash cycle. With the lower portion of the pouch substantiallyclosed, it may then be filled with a predetermined quantity of detergentand fabric softener/antistat from the hollow interior of the mandrel.Following the filling step, the tube-shaped pouch pre-form is indexeddownwardly on the mandrel and a similar row of intermittent heat-sealedlines partially closes the upper edge of the tube preform. The fabric isthen severed from the upward adjacent fabric sheet, which will then formthe next pouch.

Referring to the drawings, the dispensing container comprises, in itsfinished form, a generally flat rectangular pouch 10 which is formed ofa single piece of porous fabric. The upper and lower edges of thetube-like preform described above are shown at 12, 14, respectively. Theouter and inner ends of the overlapping portion are shown at 16, 18,respectively, and the side edges of the pouch are formed by folds 20, 22where the longitudinal sides of the original tube-like pre-form havebeen flattened, but not heat-sealed, into the thin rectangular pouch.

The continuous longitudinal heat-sealed joint between the overlappedinner and outer ends 16, 18 is shown at 24. The top and bottomtransverse rows of intermittent heat seal lines are identical. Each rowconsists of a long heat-sealed line 26 which spans across the entirezone of overlap where the two longitudinal edges of the fabric arejoined together to prevent such edge from becoming snagged during theagitation of the pouch in the washing and drying machines. Each row alsoincludes a heat-sealed line 28 at the extreme sides of pouch 10 to helpeliminate puckering of the fabric at the supplementary openings adjacentits side folds.

Between lines 26 and 28 are a series of three spaced short heat-sealedlines 30 which define therebetween a series of slots 32 which formsupplementary openings for a purpose to be explained below. FIG. 2illustrates in cross-section the heat seal lines 26, 28 and 30 where thetwo opposed (i.e., front and back) walls of the pouch have been fusedtogether, leaving narrow openings 32 therebetween.

FIG. 3 is a further enlarged sectional view through the longitudinallyheat-sealed portion of the pouch, showing also detergent granules 34 andsoftener/antistat chips 36. In the preferred embodiment, chips 36 areformed with at least several corners, to reduce the tendency of suchchips to segregate themselves within the surrounding detergent granules,thereby assuring a uniform mixture of detergent and softener/antistatduring the storage of the mixture and its subsequent loading into theindividual pouches. These corners also aid in preventing undesired exitof the chips from openings 32 of the pouch.

It will be seen from FIG. 1 that the top and bottom transverse rows ofheat seals are each spaced from the extreme top and bottom edges 12, 14of the pouch. The projecting free, unjoined edges of fabric perform ashape-retaining function which helps retain openings 32 in a flat,unpuckered condition, as shown in FIG. 2. This arrangement helps inpreventing the small detergent granules 34 from being prematurely dustedout of pouch 10.

A preferred embodiment of pouch 10 is about five inches square, with thetransverse rows of heat seals being spaced about three-eighths of aninch edges 12, 14. The slots or openings 32 are about 5-6 millimeterslong (measured along the row from side 20 to side 22). This slotdimension is selected for use with a fabric softener/antistat chip whichis about one and one-half by five by five millimeters. This dimensionalrelationship between the chips and the slot size will prevent the chipsfrom passing through the slots, because the long dimension of the slotwill decrease as its narrow dimension widens or puckers. As will beappreciated from the subsequent discussion, it is desirable that theslots 32 be as large as possible, while still preventing passage ofchips 36, to provide maximum volume of water flow therethrough.

When the pouch is placed in a washing machine, preferably with theclothes initially piled on top of it, the subsequent submergence of thepouch and agitation and impacting by the weight of the wet clothes willcause a pumping action of water in both directions through slots 32.This pumping action will tend to cause the fabric surrounding each slotto flex, allowing the shape of the slots to periodically become morerounded and less narrowed, which in turn will permit particles ofundissolved detergent to exit the pouch. Thus, supplementary openings orslots 32 perform a valve-like function, normally preventing prematuredusting or dispensing of the pouch contents prior to exposure to thewash cycle, while supplementing and enhancing the rate of water flowwhich is provided through the pores of the fabric. Adequate water flowthrough the pouch is essential to assure complete and rapid dispensingand dissolving of the detergent during the wash cycle and before therinse cycle, even under cold water wash conditions.

It is preferred, but not essential, that two opposite edges of the pouchbe provided with slots 32 to assure adequate water flow. Alternatively,a different number or relationship of the slotted edges could beprovided. However, the illustrated arrangement is considered optimum,both from a performance standpoint and for ease of fabrication of thepouch. The number of slots is not critical, provided that an adequatewater flow path is established and a chip-to-slot dimensionalrelationship is provided which precludes premature dispensing of thefabric contents.

In order to achieve rapid dispersement of preferred detergentcomposition and delayed release of the preferred fabricsoftener/antistat, pouch fabric porosity, as measured by the Frazier airpermeability method (ASTM D737), should be from about 80 to about 500cfm/ft² and more preferably from about 150 to about 300 cfm/ft². Whenused with the preferred laundry additives of this invention, a greaterporosity than that set forth may cause dusting of the dry contents andtends to cause excessive spotting of the clothing by the fabricsoftener, while a lesser porosity hinders detergent and fabricsoftener/antistat dispensing action. It will be apparent to thoseskilled in the art that the desired porosity of the pouch fabric willdepend somewhat on the physical dimensions of the laundry additivesenclosed therein. Both the fabric porosity as well as the placement andrelative size of the pouch slots set forth in the preferred embodimentof this invention are crucial to attaining the proper sequentialdispensing of the preferred laundry detergent and preferred fabricsoftener/antistat.

Fabric Softener/Antistat Composition

As shown in FIG. 4, the preferred dryer phase-effective agent in thepresent invention is a fabric softener/antistat composition in the formof flakes or chips 36. Fabric softening and antistatic agents are wellknown to those skilled in the art and include cationic and nonioniccompositions having melting points in the range of from about 25° C. toabout 110° C. In order to delay the release of the fabricsoftener/antistat until the drying cycle, the composition must have amelting point of about 40°-60° C., which is greater than thosetemperatures encountered in typical automatic washers. The preferredfabric softener/antistat must, however, melt in the range oftemperatures encountered in automatic dryers, which is typically 40°-80°C.

The preferred fabric softener/antistat flakes contain a mixture of acationic fabric softener and a nonionic antistatic agent. Thecationic/nonionic blend comprises from about 45 percent to about 55percent by weight of the fabric softener/antistat flakes. Cationicfabric softener comprises from about 30 percent to about 40 percent ofthe fabric softener/antistat flakes by weight, and those suited for usein the present invention generally include quarternary ammoniumcompounds having one or more alkyl group of about 12 to about 24 carbonatoms. Quarternary ammonium compounds having the formula: ##STR1##wherein R1 is an alkyl group having from about 12 carbon atoms to about24 carbon atoms; R2 is an alkyl group having from about 12 carbon atomsto about 24 carbon atoms; R3 is an alkyl group having from about 1 toabout 5 carbon atoms; R4 is an alkyl group having from about 1 to about5 carbon atoms; and X⁻ is selected from the group of anions includingfluorine, chlorine, bromine, phosphate and methylsulfate radicals, areacceptable. Preferred cationic fabric softeners includedicetyldimethylammonium chloride, bis-docosyldimethylammonium chloride,didodecyl-dimethylammonium chloride, ditallowalkyldimethylammoniumbromide, ditallowalkyldiethylammonium chloride,ditallowalkyldipropylammonium bromide, ditallowalkyldibutylammoniumfluoride, cetyldecylmethylethylammonium chloride,tris-[ditallowalkyldimethylammonium]phosphate and the like. Mostpreferred are the quarternary ammonium sulfate compounds such asdihydrogenated tallowdimethylammonium methylsulfate.

Suitable nonionic antistatic agents for use in the present invention arewell known to those skilled in art. Nonionics comprise from about 10percent to about 20 percent by weight of the fabric softener/antistatflakes. These include ethoxylated fatty acids, fatty alcohols, fattyglycerides, polyethylene glycols, amine oxides, diamine compounds,sorbitan esters and alkyl amines. Preferred is ethoxylated stearic acidpresent in a range of from about 13 to about 16 percent by weight of thefinal fabric softener/antistatic chips. The cationic fabricsoftener/nonionic antistat blend must be either substantiallywater-insoluble itself or substantially water insoluble when mixed withother components so that when it is formed into flakes, the flakesresist deterioration and solubilization when subjected to the washerenvironment. The fabric softener/antistat blend or solubility-modifiedblend must additionally have a melting point of about 40° C., to about60° C., to prevent melting in the washer while still permitting theflakes to melt and thus dispense in the dryer.

In order to prevent premature solubilization of the fabricsoftener/antistat, and to increase the structural integrity of thefabric softener/antistat flakes, the fabric softener/antistat blend ismixed with a dispersion inhibitor which improves the wash endurance ofthe flake and decreases the fabric softener/antistat solubility so thatthe flakes do not substantially dissolve in the wash cycle. Bysubstantially dissolve, it is meant that by weight, 60 percent to 70percent of the fabric softener/antistat survives wash and rinse cyclesof up to 50° C. in the presence of detergent. Suitable dispersioninhibitors which provide both structural integrity to the fabricsoftener/antistat flakes and also which decrease the solubility of theflakes generally include fatty alcohols having from about 14 to about 26carbon atoms in a concentration of about 25 percent to about 35 percentby weight of the fabric softener/antistat flakes. Suitable fattyalcohols within this range include myristyl alcohol, cetyl alcohol,stearyl alcohol, arachidyl alcohol, behenyl alcohol, and mixturesthereof. It will be apparent to those skilled in the art that there maybe other suitable solubility modifiers which can be used which alsoprovide the necessary structural integrity to the fabricsoftener/antistat flakes to resist deterioration during the wash cycle.

During the drying cycle, the fabric softener/antistat flakes melt insidethe pouch and wick through the fabric to the outer pouch surfaces. Therate of penetration of the fabric softener/antistat through the pouchfabric is a function of the melt viscosity and the fabric porosity. Inthe preferred range of fabric porosity, it has been found that a meltviscosity of from about 15,000 centipoise to about 75,000 centipoise isnecessary to ensure even distribution of the fabric softener/antistatonto the laundered fabrics without producing significant spotting. Afabric softener/antistat melt viscosity less than 15,000 centipoiseallows the melt to penetrate a pouch of the preferred porosity tooquickly, which produces spotting of the fabric softener/antistat onlaundry surfaces. A melt viscosity in excess of 75,000 centipoiseretards the rate of dispersion such that insufficient fabric softenerantistat is transferred to the laundered fabric surfaces within atypical drying cycle of 40 to 60 minutes.

To obtain a melt viscosity of the preferred dispersion-inhibitedcationic/nonionic fabric softener/antistat blend with this range, it hasbeen found that the dispersion inhibitor and fabric softener/antistatblend must further be combined with a thickener. In practice, thecationic/nonionic fabric softener/antistat blend is melted, whereuponthe requisite quantity of dispersion inhibitor is then added. To thismelt, thickener is added until the viscosity reaches the preferredrange. It will be apparent to those skilled in the art that the additionof thickeners may also elevate the melting point of the fabricsoftener/antistat flakes somewhat. There are many acceptable thickenersknown to those skilled in the art. These include the fumed orprecipitated silicas, bentonite, kaolin clay and organic clays. Inaddition, zeolites, calcium phosphate, diatomaceous earth and the likemay be useful herein. A precipitated fully hydrated silica, such as thatsold by the PPG Corporation under the trademark Hi-Sil T-600, isespecially preferred.

In order to further provide greater wash cycle integrity of the fabricsoftener/antistat flakes, and to prevent segregation of the flakes fromthe granular detergent composition during manufacture, the fabricsoftener/antistat flakes are formed in a generally rectangular shapehaving dimensions of from about 2 millimeters in length, 2 millimetersin width, and a thickness of 1 millimeter to a length of about 6millimeters, width of 6 millimeters and a thickness of 3 millimeters. Ofcourse, it may acceptable to deviate from these dimensions somewhat toform the flakes in other than rectangular form while still maintainingthe requisite stability in the wash cycle and eliminating anysegregation problems.

While a greater quantity of fabric softener/antistat composition may beadded to each preferred pouch, we prefer a fill weight range of fromabout 1 to about 8 grams fabric softener/antistat, with a preferredrange of about 1.5 to about 3 grams per pouch. Preferably, the fabricsoftener/antistat flakes contain perfume which is carried over into thedryer for release there.

Detergent

In accordance with the present invention, the detergent composition mustprovide sufficient detersive action in a quantity of the compositionwhich will loosely fill the chamber of the dispenser pouch. A fillweight range of detergent composition of from about 20 to about 100grams of detergent composition per pouch is acceptable, with a detergentfill weight of from about 40 grams to about 60 grams per pouchpreferred. The detergent composition of this invention must disperserapidly and completely in the wash water at the beginning of the washcycle. If the detergent does not fully dispense during the wash cycle,it may leave an undesirable, visible residue on laundered fabrics. It isthus desirable to provide a rapidly soluble, non-caking detergentcomposition in order to facilitate rapid dispersement of the detergentfrom the preferred pouch into the wash water. By non-caking, it is meantthat the detergent granules do not agglomerate in either the dry or wetstate to particle sizes which will impede the flow of detergent throughthe pores and side valves of the preferred pouch. The detergentcomposition of the present invention provides free-flowing granuleshaving excellent solubility characteristics. The granule size, asmeasured by the Tyler mesh scale, should be between 10 mesh and 100mesh.

Laundry detergent compositions contain a surfactant to providesoil-dispersing and emulsifying properties which form the basis ofdetergency action. Surfactants suitable for use in detergents are wellknown to those skilled in the art and include surfactants selected fromthe group consisting of anionic, cationic, nonionic, ampholytic,zwitterionic, and combinations thereof. Surfactant comprises from about5 percent to about 25 percent, and preferably from about 12 percent toabout 15 percent by weight of the detergent composition herein. In thepreferred embodiment, nonionic detergent surfactants of the typeincluding those produced by the condensation of hydrophobic, aliphaticor alkyl aromatic compounds with hydrophilic, alkylene oxide compoundsare utilized. Nonionic detergent surfactants useful in the presentinvention include those obtained through the condensation of aliphaticalcohols having straight or branch carbon chains of from about 10 toabout 20 carbon atoms, with 3 to 15 moles of ethylene oxide for eachmole of aliphatic alcohol. It will be apparent to those skilled in theart that the carbon chain length between hydrophilic and hydrophobicsurfactant components can be controlled to produce the desired watersolubility characteristics and that other alkylene oxides, such asbutadiene dioxide, can be used to produce suitable nonionic surfactants.The most preferred surfactants for use in the present invention are thecondensation products of fatty alcohols having from about 12 to about 15carbon atoms with 7 moles of ethylene oxide.

In addition to a surfactant, the detergent composition herein containsone or more sequestering agents to inactivate metallic ions which arepresent in the wash water. Suitable sequestering agents will be known tothose skilled in the art and include such phosphate builders as sodiumtripolyphosphate, potassium tripolyphosphate, orthophosphate, andpyrophosphate. It will be recognized that non-phosphate builders mayalso be used effectively. In order to promote rapid solubility of thedetergent composition and to provide resistance to caking, it has beenfound necessary to prehydrate the phosphate builder so that the hydratedphosphate contains from about 15 percent to about 25 percent by weightof water. We prefer to hydrate in a rotary agglomerator in order toobtain granules with high absorbtivity. Medium density granularpentasodium triphosphate hydrated with soft water to a final weight offrom about 15 percent to about 25 percent water has been found to bemore useful in achieving the requisite solubility characteristics. Thehydrated phosphate builder constitutes from about 30 to about 60 percentby weight of the detergent composition of this invention.

The granular detergent composition of the present invention alsocontains from about 8 percent to about 20 percent by weight of anon-phosphorous, inorganic detergent builder such as sodium carbonate,potassium carbonate, or sodium sesquicarbonate or combinations thereofto provide alkalinity to the wash liquor and to precipitate metallicions. It has found that from about 8 percent to about 20 percent ofsodium carbonate by weight of final detergent composition providesexcellent alkaline cleansing power in the present invention. Sodiumcarbonate content in excess of 20 percent by weight of the finaldetergent composition produces unacceptable levels of caking.

The preferred detergent composition also contains from about 1 to about7 percent by weight of the final detergent composition of a soilanti-redeposition agent to help prevent soil from resetting on fabricsafter it has been removed during washing. Suitable anti-redepositionagents which are useful in the present invention include sodiumcarboxymethylcellulose, polyacrylates, polyvinyl pyrrolidone, polyvinylalcohol and polyethylene glycol. Polyacrylate provides particularly gooddispersant action for particulate solids such as clay, dirt and thelike. In the preferred embodiment, the detergent of the presentinvention contains about 1 percent to about 2 percent by weightcarboxymethyl cellulose and up to about 5 percent by weight sodiumpolyacrylate.

In addition to a surfactant, the detergent composition of the presentinvention may also contain up to 5 percent by weight of the finaldetergent composition of a washer-effective fabric softener/antistaticagent. Although nonionic and amphoteric surfactants do provide somefabric softening/antistatic action, substantially water insolublecationic surfactants selected from the class of quarternary ammoniumsalts are preferred for use herein. In particular, quarternary ammoniumchloride salts having one or preferably two fatty acid radicals of fromabout 8 to about 24 carbon atoms in length are useful herein.Dialkyldimethylammonium chlorides having alkyl groups of from about 12to 22 carbon atoms, which may be produced from long chain fatty acids,are especially washer-effective fabric softeners/antistats. Specificquarternary ammonium compounds which are useful in the present inventionare dihexadecyldimethylammonium chloride, dioctadecyldimethylammoniumchloride and dihexadecyldiethylammonium chloride or the correspondingsulfate salts. We have found distearyldimethylammonium chloride toprovide excellent results.

In addition, the detergent composition herein contains up to about 36percent by weight of a suitable filler to provide the appropriatedetergent composition density. The bulk density of the preferreddetergent herein may be as low as 0.3 grams per cubic centimeter with apreferred range of from about 0.65 g/cc to about 0.75 g/cc. It has beenfound that a density below 3 g/cc requires a rather large pouch tocontain an effective amount of detergent. Suitable fillers for use inthe present invention will be apparent to those skilled in the art. Inthe preferred embodiment, sodium sulfate is used.

The detergent herein may also contain up to 1 percent of an enzymemixture to help break down certain soils and stains to simpler forms.These soils and stains can then be more easily removed during thelaundering process. A mixture of a proteolytic enzyme and an amylolyticenzyme is preferred.

It will be obvious to those skilled in the art that otherfabric-enhancing agents which are compatible with the preferreddetergent components could be incorporated into the detergentcomposition in accordance with the broader aspects of the presentinvention and may include certain optical brighteners, germicides,perfumes, waterproofing agents, sizing agents, other soil releaseagents, bleaches, fabric fresheners, and the like. Thus, it isunderstood that the above is merely a preferred embodiment of theinvention and that various changes and alterations can be made withoutdeparting from the spirit and broader aspects thereof as set forth inthe appended claims which are to be interpreted in accordance with theprinciples of patent law, including the doctrine of equivalents.

In Use

In use, the preferred dispenser pouch, containing from about 1 gram toabout 3 grams of the preferred softener/antistat and from about 40 gramsto about 60 grams of the preferred detergent, is placed in the bottom ofa washing machine tank. Laundry is then placed in the tank on top of thepouch. The desired wash and rinse cycles are programmed and the washcycle is started. As water reaches the pouch, it enters the pouchchamber through the side valves as well as through the pouch fabric. Thepouch fabric is then wetted out and a detergent slurry is formed. Whenmechanical agitation of the washer begins, the pouch is repeatedlycompressed and released by the laundry load as both pouch and laundrymove about the tank interior in response to the agitator action. Thiscycle of compression and release causes the pouch side valves torepeatedly open and close. When the pouch is compressed, multiple valvesopen and the detergent slurry is forced through the valve openings intothe wash liquor and solubilized detergent is forced through the pores.Shortly after the beginning of the wash cycle, the majority of thedetergent is in solution in the wash liquor. The fabricsoftener/antistat chips, being somewhat larger than the valve openings,are retained in the pouch chamber during the wash and rise cycle. By theend of the first three minutes of the wash cycle, essentially all of thedetergent has left the pouch chamber.

Following the rinse and spin dry cycles, the damp laundry and the pouchare transferred to the automatic dryer. During the drying cycle, thepouch quickly dries before most other laundered fabrics. As the pouchand fabric softener/antistat chips heat to the internal temperature ofthe dryer, the chips melt and wick through the pores of the pouchfabric, coating the pouch exterior. The coated pouch tumbles with thelaundry load and the fabric softener/antistat composition is transferredfrom the exterior pouch surfaces to the laundry surfaces by physicalcontact. The treated laundry is thereby sequentially cleaned andsoftened and rendered essentially static-free.

EXAMPLE

The preferred dispenser was formed by folding a sheet of non-woven,spun-bonded polypropylene fabric having an average weight of 1.5 oz./yd²and an air permeability of 200 cfm/ft² into the shape of a tube whichwas ultrasonically heat sealed along the longitudinal fabric overlap.One end of the fabric tube was then ultrasonically heat sealed to forman intermittent seal line recessed approximately three-eighths of aninch from the edge of the pouch fabric. The intermittent slots wereabout 3-6 millimeters long.

The preferred detergent composition was prepared by first prehydratingthe sodium tripolyphosphate in a rotary agglomerator and then mixing thedry ingredients according to the following formula:

    ______________________________________                                        Ingredient              % by weight                                           ______________________________________                                        Fully Hydrated Sodium Tripolyphosphate                                                                43.5                                                  Nonionic Detergent Surfactant                                                                         14.25                                                 Perfume                  .15                                                  Sodium Carbonate        16.00                                                 Sodium Sulfate          5.80                                                  Carboxymethyl Cellulose 1.60                                                  Fluorescent Whitening Agent                                                                            .35                                                  Distearyldimethylammonium Chloride                                                                    2.25                                                  Sodium Polyacrylate     1.50                                                  Sodium Metasilicate Pentahydrate                                                                      14.00                                                 Protease and Amylase Blend                                                                             .60                                                  ______________________________________                                    

Fifty grams of the remaining detergent was then mixed with 1.8 grams ofthe preferred fabric softener/antistat which was prepared in accordancewith the following formula:

    ______________________________________                                        Ingredient               % by weight                                          ______________________________________                                        Dihydrogenated Tallow Dimethyl Ammonium                                                                35.70                                                Methyl Sulfate                                                                Ethoxylated Stearc Acid  15.30                                                Stearyl Alcohol          30.00                                                Fully Hydrated Precipitated Silica                                                                     15.00                                                Perfume                   4.00                                                ______________________________________                                    

The fabric softener/antistat was prepared in a molten state with aviscosity of about 30,000 to 40,000 centipoise and extruded in ribbonswhich were cut to a length of 5 millimeters. The fabricsoftener/antistat chips were 5 millimeters wide and 11/2 millimetersthick. The detergent and fabric softener/antistat mixture was thenplaced inside the preferred pouch. The fill weight of the compositionwas 51.8 grams. The open pouch end was then ultrasonically heat sealedshut in a manner identical to the first end. The pouch was placed insidea machine washer and soiled test fabrics were added to make an averagelaundry load. The washer was then run through wash, rinse, and spin drycycles. After the spin dry cycle, the laundry load and pouch weretransferred to a machine dryer where the laundry load was fully dried.The laundry was removed and observed to be clean, soft and substantiallystatic-free.

What is claimed is:
 1. The method of packaging a mixed quantity of firstand second distinct materials for subsequent release from the package ina phased sequence whereby substantially all of the first material butless than a majority of the second material will be automaticallyreleased from the package when the package and its contents aresubjected to a first set of ambient conditions, and the majority of thesecond material will be automatically released from the package onlywhen the package and its contents are subjected to a second set ofambient conditions, the first material being fully water soluble and thesecond material being no more than partially water soluble under thefirst set of ambient conditions, and the second material having amelting point which is above the temperatures normally encounteredduring the first set of ambient conditions but which is less than thetemperatures encountered during the second set of ambient conditions,the method comprising the steps of:(1) forming a pouch-like dispensingpackage from a porous fabric, with the porosity being selected to permitpassage of water and of said second material when in its meltedcondition but to normally prevent passage of either of said first andsecond materials therethrough when said package is kept out of water andbelow the melting point of said second material; (2) forming a pluralityof supplementary openings in said package, which openings are normallyin a substantially closed condition wherein the minimum dimension ofeach of said openings is small enough relative to the form anddimensions of said first and second materials that no more than aninsignificant amount of said first material and none of said secondmaterial will pass therethrough during normal handling of said package,said openings tending to remain in their substantially closed conditionas a result of the natural lay of the fabric, the shape of said package,and the placement of said openings therein, but said openings tending toenlarge their minimum dimension when said package is exposed to thefirst set of ambient conditions, including simultaneous submergence inwater, agitation and impact, the enlarged condition of said openingspermitting an increased rate of water flow into and out of said packageto effect complete dispensing of undissolved and dissolved portions ofsaid first material from the package while still being small enoughrelative to the form and dimensions of said second material to preventdispensing of said second material from said package; and (3) placing adesired mixture of said first and second materials into said package andclosing said package except for said pores and supplementary openings.2. The packaging method of claim 1 wherein said first and secondmaterials are laundry additives and said first and second set of ambientconditions are the washing and drying phases of a machine clotheswashing and drying operation, respectively.
 3. The packaging method ofclaim 2 wherein said first additive is a clothes washing detergent. 4.The packaging method of claim 2 wherein said second additive is a fabricsoftener/antistat.
 5. The packaging method of claim 2 wherein said firstadditive is a clothes washing detergent and said second additive is afabric softener/antistat.
 6. The packaging method of claim 1 whereinsaid package is formed by the steps of:(1) joining two overlapping edgesof said fabric together along a first longitudinal joint to form atube-shaped pouch pre-form having first and second open ends; (2)joining opposed walls of said tube-shaped preform along a transverseline adjacent a first open end of said pre-form; (3) filling theinterior of said pre-form with a predetermined mixture of said first andsecond materials; and (4) joining said opposed walls of said pre-formalong a second transverse line adjacent the other open end of saidpre-form to form a generally flat rectangular pouch which contains saidfirst and second materials; (5) at least one of said transverse lines ofjoinder being interrupted by portions of said opposed walls which arenot joined, to thereby define said plurality of supplementary openings.7. The packaging method of claim 6 wherein said joining steps areperformed by a heat sealing process.
 8. A method of packaging anddispensing a predetermined quantity of clothes washing detergent and afabric softener during a machine clothes washing and drying cycle,comprising the steps of:(1) packaging a mixture of water solubledetergent in granular form and a substantially less soluble fabricsoftener/antistat in large chip form in a chamber defined by porousfabric formed into a pouch-like container; (2) forming said fabricsoftener/antistat chips of a material the majority of which will remainunmelted and undissolved during the conditions normally encountered inthe washing and rinsing cycle, but which will melt during the highertemperature conditions of the drying cycle and pass through said fabricpores to coat the outside of said container for subsequent transfer tothe clothing during the drying cycle; (3) selecting the fabric porosityand the particle size of said detergent such that water can flow throughsaid fabric but said detergent particles, when in undissolved form,cannot pass through said fabric; (4) forming said container by the stepsof:(a) joining two overlapping edges of said fabric together along afirst longitudinal joint to form a tube-shaped pouch pre-form havingfirst and second open ends; (b) joining opposed walls of saidtube-shaped preform along a transverse line adjacent a first open end ofsaid pre-form; (c) filling the interior of said pre-form with apredetermined mixture of said detergent and fabric softener/antistat;and (d) joining said opposed walls of said pre-form along a secondtransverse line adjacent the other open end of said pre-form to form agenerally flat rectangular pouch which contains said detergent andfabric softener/antistat; (e) at least one of said transverse lines ofjoinder being interrupted by portions of said opposed walls which arenot joined, to thereby define a plurality of supplementary openings; (5)forming said supplementary openings so that they are normally maintainedin a substantially closed condition by the configuration andconstruction of said container, in which condition no more than aninsignificant amount of said detergent particles will pass therethroughduring normal handling of said container prior to use, but saidsupplementary openings tending to enlarge once said container issubjected to flexing and impact induced by agitation, impact and watersubmergence during a clothes washing cycle, whereby an increased rate ofwater flow into and out of said container will effect completedispensing of undissolved and dissolved portions of said detergent fromsaid container during the clothes washing cycle when said container isinitially placed in a clothes washing machine along with a load ofclothes to be washed; and (6) selecting the size and shape of saidsupplementary openings relative to the size and shape of said fabricsoftener/antistat chips such that said chips will not pass through saidsupplementary openings under any normally encountered conditions belowthe melting point of said chips; (7) whereby said container can beplaced in a clothes washing machine with the clothes to be washed, andsubstantially all of said detergent but less than a majority of saidfabric softener/antistat will be automatically dispensed from saidcontainer during the washing cycle, thereafter said container beingtransferred with the washed clothes to the clothes drying machine,wherein said fabric softener/antistat will be dispensed from saidcontainer.
 9. The packaging method of claim 8 wherein said joining stepsare performed by a heat sealing process.
 10. The packaging method ofclaim 8 wherein each of said fabric softener/antistat chips has a volumebetween about 0.004 cubic centimeters and about 0.11 cubic centimeters.11. A package from which a mixed quantity of first and second laundryadditives can be released in a phased sequence in response to thediffering conditions of the washer phase and dryer phase of a clotheswashing and drying operation, comprising:a pouch-like container formedof porous fabric material and containing a first granular laundryadditive which is substantially fully water soluble under the washerphase conditions and a second laundry additive present in the form oflarger chips, said second additive having a melting point which is abovethe temperatures normally encountered in the washer phase, the majorityof said second laundry additive being water insoluble during the washerphase; said porous fabric having a porosity selected to permit passageof water and of said second laundry additive when said second laundryadditive is in its melted condition, but to normally prevent passage ofeither of said first and second laundry additives therethrough when saidpackage is kept out of water and below the melting point of said secondlaundry additive; said container being provided with a plurality ofsupplementary openings, which are normally maintained in a substantiallyclosed condition as a result of the natural lay of said fabric, theshape of said container and the placement of said openings therein, butsaid openings and said container being so constructed that said openingstend to enlarge when said container is subjected to the conditions ofthe washer phase, including simultaneous submergence in water, agitationand impact of said container; said enlarged condition of said openingspermitting an increased rate of water flow into and out of saidcontainer to effect complete dispensing of said first laundry additiveduring said washer phase; in said substantially closed condition of saidopenings the minimum dimension across each of said openings being smallenough relative to the form and size of said first laundry additiveparticles to normally permit no more than an insignificant amount of thedry first laundry additive to pass therethrough during normal handlingof said container and to permit substantially none of said secondlaundry additive chips to pass therethrough during normal handling ofsaid container and during said washer phase; and in said enlargedcondition of said openings the minimum dimension across each of saidopenings remaining small enough relative to the size and shape of saidsecond laundry additive chips to prevent passage of any unmelted chipstherethrough; whereby when said container and its contents are subjectedto said washer phase, including submergence in water, agitation andimpact, substantially all of said first laundry additive will bedispensed therefrom in dissolved form through the porous fabric and indissolved and undissolved form through said supplementary openings, withthe majority of said second laundry additive remaining undispensedwithin said container throughout said washer phase, and when saidcontainer and its remaining contents are subjected to said dryer phase,including a temperature above the melting point of said second laundryadditive, said chips will melt and said second laundry additive willwick through said fabric pores and coat the outside of said container.12. The package of claim 11 wherein said first laundry additive is aclothes washing detergent.
 13. The package of claim 12 wherein saiddetergent comprises:(a) from about 5% to about 25% by weight of anorganic significant; (b) from about 30% to about 60% by weight of afully hydrated phosphate detergent builder; (c) up to about 20% byweight of a non-phosphate detergent builder; (d) from about 1% to about7% by weight of a soil antideposition agent.
 14. The package of claim 11wherein said second laundry additive is a fabric softener/antistat. 15.The package of claim 14 wherein each of said fabric softener/antistatchips has a volume between about 0.004 cubic centimeters and about 0.11cubic centimeters.
 16. The package of claim 14 wherein said fabricsoftener/antistat comprises:(a) from about .[.45% to about 55% .]..Iadd.30% to about 40% .Iaddend.by weight of a quaternary ammoniumcompound having at least one alkyl group of about 12 to about 24 carbonatoms; (b) from about 10% to about 20% by weight of a nonionicantistatic agent; (c) from about 25% to about 35% by weight of a fattyalcohol having from about 14 to about 26 carbon atoms; (d) a quantity ofviscosity modifier sufficient to raise the fabric softener/antistatcomposition melt viscosity to within the range of about 15,000centipoise to about 75,000 centipoise.
 17. The package of claim 14wherein said fabric softener/antistat has a melt viscosity of betweenabout 15,000 centipoise to about 75,000 centipoise, and said pouchfabric has a porosity of between about 150 cubic feet per minute persquare foot to about 300 cubic feet per minute per square foot.
 18. Thepackage of claim 11 wherein said first laundry additive is a clotheswashing detergent and said second laundry additive is a fabricsoftener/antistat.
 19. The package of claim 11 wherein saidsupplementary openings are located in an interrupted line of joinderbetween opposed walls of said container, said line of joinder partiallyclosing one end of the package, the interruptions between the joinedportions along said line defining said supplementary openings.
 20. Thepackage of claim 19 wherein said interrupted line of joinder is formedby a heat sealing process.
 21. The package of claim 19 wherein said lineof joinder is spaced slightly from said end of the package so that theportion of said fabric walls between said line of joinder and said endof the package aids in normally maintaining said supplementary openingsin a substantially closed condition.
 22. A package from which a mixedquantity of first and second laundry additives can be released in aphased sequence in response to the differing conditions of the washerphase and dryer phase of a clothes washing and drying operation,comprising:a pouch-like container formed of a porous fabric material andcontaining a first laundry additive which is effective during the washerphase and which is substantially fully water soluble under the waterphase conditions, and a second laundry additive which comprises a fabricsoftener/antistat which is present in the form of particles each havinga volume of between about 0.004 cubic centimeters and about 0.11 cubiccentimeters and which has a melting point which is above thetemperatures encountered in the washer phase, the majority of saidfabric softener/antistat being water insoluble during the washer phase;said porous fabric having a .[.porous.]. .Iadd.porosity .Iaddend.ofbetween about 150 cubic feet per minute per square foot and about 300cubic feet per minute per square foot, and said fabric softener/antistathaving a melt viscosity of between about 15,000 centipoise and about75,000 centipoise, said fabric porosity permitting passage of water andof said fabric softener/antistast when it is in its melted condition,but normally preventing passage of either of said first laundry additiveand said fabric softener/antistat therethrough when said package is keptout of water and below the melting point of said fabricsoftener/antistat; said fabric softener/antistat comprising from about.[.45.]. .Iadd.30 .Iaddend.percent to about .[.55.]. .Iadd.40.Iaddend.percent by weight of a quaternary ammonium compound having atleast one alkyl group of about 12 to about 24 carbon atoms, from about10 percent to about 20 percent by weight of a nonionic antistatic agentand from about 25 percent to about 35 percent by weight of a fattyalcohol having from about 14 to about 26 carbon atoms. .Iadd.
 23. Apackage from which a mixed quantity of first and second laundryadditives can be released in a phased sequence in response to thediffering conditions of the washer phase and dryer phase of a clotheswashing and drying operation, comprising:a pouch-like container formedof a porous fabric material and containing a first laundry additivewhich is effective during the washer phase and which is substantiallyfully water soluble under the water phase conditions, and a secondlaundry additive which comprises a fabric softener/antistat which ispresent in the form of particles each having a volume of between about0.004 cubic centimeters and about 0.11 cubic centimeters and which has amelting point which is above the temperatures encountered in the washerphase, the majority of said fabric softener/antistat being waterinsoluble during the washer phase; said porous fabric having a porosityof between about 150 cubic feet per minute per square foot and about 300cubic feet per minute per square foot, and said fabric softener/antistathaving a melt viscosity of between about 15,000 centipoise and about75,000 centipoise, said fabric porosity permitting passage of water andof said fabric softener/antistat when it is in its melted condition, butnormally preventing passage of either of said first laundry additive andsaid fabric softener/antistat therethrough when said package is kept outof water and below the melting point of said fabric softener/antistat;said fabric softener/antistat comprising from about 30 percent to about40 percent by weight of a quaternary ammonium compound having at leastone alkyl group of about 12 to about 24 carbon atoms, from about 10percent to about 20 percent by weight of a nonionic antistatic agent andfrom about 25 percent to about 35 percent by weight of a dispersioninhibitor which improves the wash endurance of the flake and decreasesthe fabric softener/antistat solubility so that the flakes do notsubstantially dissolve in the wash cycle. .Iaddend. .Iadd.24. Thepackage of claim 23 in which said fabric softener/antistat additionallyincludes a sufficient thickener to give said fabric softener/antistat amelt viscosity of from about 15,000 centipoise to about 75,000centipoise. .Iaddend. .Iadd.25. The package of claim 24 in which saidthickener is selected from the group comprising fumed or precipitatedsilicas, bentonite, kaolin clay, organic clays, zeolites, calciumphosphate and diatomaceous earth. .Iaddend. .Iadd.6. The package ofclaim 25 in which said dispersion inhibitor comprises a fatty alcoholhaving from about 14 to about 26 carbon atoms.